MFGE 2421 Intro to Additive Manufacturing

Department of Manufacturing Engineering

03/15/2019, Statesboro, Georgia, USA

Technical Report

BRACKET OPTIMIZATION

Shawn Wilkes
Georgia Southern University
Statesboro GA, USA

1 Copyright © 2019 by ASME

ABSTRACT

The purpose of this project was to take a bracket design and reduce its overall weight by 30%. Reverse

engineer a bracket with specific parameters while maintaining structural integrity. The stress will be observed

using the simulation express tool in the Solid-works program. The new bracket will be designed and tested also

using the solid works simulation express then compared to original bracket design to assure the max stresses are

lower than the safety stresses. The project requires two designs in effort to design a bracket with the reduced mass

and test their structural integrity.

INTRODUCTION

Optimization is an essential part of the manufacturing process. Making parts more lightweight while

maintaining structural integrity can save on costly materials, especially in a mass production. The ability to

remove excess martial needed for designs can also benefit structures required to more lightweight such as

aerospace or aeronautic. Making a sleek design that benefits the part structural integrity is both economically and

is some cases aesthetically proficient.

DESIGN CONCEPT

The original bracket was measured (fig 1.) and recreated in Solid works (fig 2). The piece was then tested

using the simulation express program. Using the simulation express utility provides the information needed to

redesign the bracket while taking the best steps to optimize its strengths while trimming away the parts useless

area.

2 Copyright © 2019 by ASME

Fig. 1 Original bracket measurements Fig. 2 Original bracket design

METHODOLOGY

The original design has a 6.5mm this base the bae is 76mm X 38mm with corners that are 2.5 in radius. The

ribs attach a tube fixture that is 25mm long with a diameter of 15 mm. The inner diameter of the tube at 10 mm.

The holes that are to affix the part are 5mm in diameter. A plane was created at the center of the cylinder tube and

a force of 50 lbs was applied at a 45-degree angle (fig 3.)

Fig. 3 pressure applied at angle

3 Copyright © 2019 by ASME

RESULTS AND DISCUSSION

Two designs were created with the intent to reduce the weight of the part by 30%. The first utilized fillets and

holes to retain structural integrity (fig. 4). The second design utilized fillets and removal of base components. The

second design also implemented removal of internal portions to reduce the overall mass (fig. 5)

Fig 4. Design 1 Fig 5. Design 2

3D PRINTING

The design was exported to an STL file for 3D printing. Some processing was needed for a better finished

product.

CONCLUSION

After refining the part, the same resilience is achieved by keeping the retaining structure intact at it most

critical points as seen in figure 6 and figure 7

4 Copyright © 2019 by ASME

Fig 6 redesigned part stress

Fig 7 original part stress

5 Copyright © 2019 by ASME